Polymerization process

ABSTRACT

The present invention relates to a process for the introduction of liquid feeds to a polymerisation process, and in particular provides a process for the introduction of a fresh feed selected from fresh comonomer and fresh inert hydrocarbon to a polymerisation reactor, which polymerisation reactor is part of a polymerisation process comprising high and low pressure recovery systems, said high pressure recovery system being at a pressure of 0.5 MPa or above and said low pressure recovery system being at a pressure of less than 0.5 MPa, which process comprises passing said fresh feed and a process stream comprising a first component selected from hydrogen, nitrogen and methane and a second component which is a monomer to a separator which is part of the low pressure recovery system and is at a pressure of 0.4 MPa or less to produce a first stream comprising the majority of the first component and a second stream comprising the second component and the majority of the fresh feed, and passing the second stream to the polymerisation reactor.

The present invention relates to a process for the introduction of liquid feeds to a polymerisation process.

The production of polymer powder by polymerisation reactions of monomers in the presence of catalysts is well-known. For example, processes are known and widely operated commercially using both fluidised bed reactors and slurry phase reactors.

In a slurry polymerisation process, for example, the polymerisation is conducted in a stirred tank or, preferably, a continuous loop reactor in which a slurry of polymer particles in a liquid medium comprising hydrocarbon diluent is circulated. During the course of polymerisation, fresh polymer is generated by the catalytic polymerisation of monomer and polymer product is removed from the reactor by removing a portion of the slurry.

The slurry withdrawn may be treated to separate the polymer particles from the hydrocarbon diluent and other components, such as unreacted monomers, which it is generally desired are recycled to the process.

A polymerisation process generally includes feed systems for fresh monomer and comonomer, as well as for fresh inert liquids. Fresh feeds of monomer and co-monomer for example are fed to the polymerisation process to replace monomer and comonomer consumed in the reaction. Although inert liquids don't react they can be lost from the system in purges or as residual amounts in the polymer passed to downstream storage and processing.

Thus, it is common to have fresh feeds for each of the process components. The fresh feeds are usually treated to remove components which may act as poisons in the polymerisation process, or which, even if not poisons, may otherwise build-up in the process and require larger purges to be taken. (Unless separation of the component is very efficient, any increase in purge rates is likely to lead to increased loss of useful materials as well.)

U.S. Pat. No. 6,051,631, for example, discloses a process to treat fluid streams to remove undesirable compounds, in particular to treat monomer, comonomer and diluent streams to a polymerisation process.

In general, treatment comprises passing the respective streams to a treatment bed, usually comprising a fixed bed of a suitable absorbent for the impurities it is desired to remove. Two or more treatment beds for a particular feed may be provided in parallel to allow one to be regenerated whilst another is in use, as described in U.S. Pat. No. 6,051,631. It is also possible that certain streams, such as diluent and comonomer, can be mixed and passed to a common treatment bed, such as also described in U.S. Pat. No. 6,051,631. The treated streams are then passed to the reactor (or reactors where more than one are present).

We have now found that introduction of fresh liquids to a polymerisation process can advantageously be achieved by not passing said streams directly to the reactor but by instead passing them to a low pressure separator which is already present in the low pressure part of the recovery system of a polymerisation process.

Thus, in a first aspect, the present invention provides a process for the introduction of a fresh feed selected from fresh comonomer and fresh inert hydrocarbon to a polymerisation reactor, which process comprises passing said fresh feed and a process stream comprising a first component selected from hydrogen, nitrogen and methane and a second component which is a monomer to a separator at a pressure of 0.4 MPa (4 bar) or less to produce a first stream comprising the majority of the first component and a second stream comprising the second component and the majority of the fresh feed, and passing the second stream to the polymerisation reactor.

In this first aspect, the fresh feed is passed to a separation step at a pressure of 0.4 MPa (4 bar) or less with a process stream comprising the first and second components. This is preferably performed by mixing the fresh feed and process stream to form a mixed stream which is passed to the separator.

The term “fresh” as used herein means a feed/component which is being passed to the reactor for the first time and can be contrasted with process streams which contain components recovered from the reactor effluent, usually for recycle. However, for avoidance of doubt “fresh” streams may have been subjected to pre-treatments to reduce impurities.

The term “process stream” as used herein means a stream which is present in the recycle and recovery system by which components which it is desired to recover from the reactor effluent are recycled to the reactor. The process stream comprises a first component selected from hydrogen, nitrogen and methane. Preferably the first component is nitrogen. However, more generally, hydrogen, nitrogen and methane may all be present in the process stream. The process stream comprises a second component which is a monomer.

The process stream will generally comprise a number of other components which are present in the polymerisation reactor. Thus, where a comonomer is fed to the process then the process stream generally also comprises comonomer. Other components which may be present include impurities associated with the main components in the reactor. For example alkanes such as ethane and propane may be present as impurities in ethylene feeds, and butane and hexane may be present as impurities in 1-butene and 1-hexene respectively.

The term “majority” as used herein means greater than 50 wt %. For example. reference to the first stream comprising “the majority of the first component” means that this stream comprises more than 50% by weight of the first component in the process stream which is fed to the separator.

The present invention is particularly applicable to the polymerisation of olefins in gas phase or slurry phase reactors.

The polymerisation reactor preferably has a volume of at least 50 m³, for example in the range 50 to 250 m³.

The polymerisation reactors may have at least 2 withdrawal ports.

The withdrawal of polymer from the polymerisation reactor may be performed continuously. Alternatively, the withdrawal of polymer from the polymerisation reactor may be performed discontinuously.

The polymerisation reactor is preferably a slurry phase polymerisation reactor.

The inert hydrocarbon is preferably iso-butane.

For avoidance of any doubt, where more than one olefin is present in the polymerisation reaction, the term “monomer” as used herein refers to the olefin which is present in the largest amount in the formed polymer, and may also be referred to as the “principal monomer”.

The monomer is preferably ethylene or propylene, most preferably ethylene. The term “comonomer” as used herein refers to olefins other than the monomer which may be present. More than one comonomer may be present.

Where ethylene is the monomer, propylene may be the comonomer, but the comonomer is preferably selected from 1-butene, 1-hexene and 1-octene, with 1-hexene being most preferred.

Where propylene is the monomer, the comonomer is preferably selected from ethylene, 1-butene, 1-hexene and 1-octene.

The comonomer is preferably 1-hexene.

The term “separator” as used herein means a process unit in which separation of vapour and liquid streams can occur. Thus, at least initially, the first stream is recovered in vapour (gas) form from the separator, whilst the second stream is recovered in liquid form. Examples of “separators” include vapour/liquid separation vessels and fractionation columns. In a vapour/liquid separation vessel a mixture of vapour and liquid is separated by allowing a liquid phase to form in the base of the vessel with a vapour phase above. The liquid phase can then be readily withdrawn from the base, and the vapour overhead. This may be considered as a “single stage” separation vessel in that the vessel may be considered to comprise just one contacting stage. In a fractionation column, in contrast, multiple stages are provided in which vapour passing upwards contacts condensing liquid flowing downwards, such that the vapour becomes enriched in more volatile components and the liquid becomes enriched in the heavier components.

Preferably, the separator is not a fractionation column, and more preferably is a single stage separation vessel, and most preferably a vapour/liquid separation vessel. In particular, the advantages detailed further herein are reduced when a fractionation column is used rather than a vapour/liquid or other single stage separation vessel.

The “separator” may also be considered as a “lights separator”, by which as used herein is meant a separator which is operated to provide a separation of the first component from monomer and heavier components. In general terms, the term “lights” as used herein means propane and molecules having a molecular weight less than propane. The separator in the present invention separates a portion of the light components said portion generally comprising hydrogen, nitrogen and/or methane (the first component). The general concept of “lights separators” for separation of light components in polymerisation processes is well-known (along with “heavies separators” for separation of “heavy” components). One example of such a system is taught by U.S. Pat. No. 6,292,191 although in this document the lights column is operated to remove hydrogen, oxygen, nitrogen and ethylene from diluent to give a purified, olefin-free, diluent stream, whereas in the present invention lights other than ethylene, such as hydrogen, nitrogen and methane, are separated from ethylene (and heavier compounds).

In the separator in the present invention at least some of the second component and the majority of the fresh feed are recovered in the second stream and the majority of the first component in the first stream. Preferably, at least 30 wt % of the second component (monomer) is recovered in the second stream, and more preferably at least 40 wt %. In some embodiments, the majority of the second component (monomer) is recovered in the second stream. In other embodiments, however, less than 50 wt % of the second component (monomer) is recovered in the second stream. For example, the second stream may comprise at least 30 wt % but less than 50 wt % of the second component.

The process of the present invention results in an improved separation of the first component from the second component (monomer).

The present invention may be applied to a gas phase polymerisation reactor/process. In a gas phase polymerisation process the fresh inert hydrocarbon may be a component which is utilised as a condensable liquid in the process. Such components are added to the reactor in liquid form, and vaporise therein, removing heat of reaction. Preferred examples of such components are butanes, pentanes and hexanes, and preferably pentanes and hexanes.

In a slurry polymerisation process the fresh inert hydrocarbon may be a component which is utilised as a diluent in the process. Such components are added to the reactor and form part of the liquid medium of the slurry in the reactor. Preferred examples of such components for use as diluents are butanes, especially iso-butane, pentanes, hexanes and mixtures thereof. Iso-butane is most preferred.

The process stream in the present invention is preferably a low pressure process stream, by which is meant a process stream which is at a pressure of less than 0.5 MPa (5 bar) even prior to the separator, preferably at a pressure of 0.4 MPa (4 bar) or less. The low pressure process stream is preferably a stream which arises from the low pressure recovery system of the polymerisation process, as described further below.

It will be apparent that the fresh feed to be fed will be or will comprise a component which may, and generally will, already be present in the process stream. Thus, where the fresh feed is an inert hydrocarbon the corresponding inert hydrocarbon will generally also be present in the process stream. Similarly, where the fresh feed is a comonomer, the corresponding comonomer will generally also be present in the process stream.

Preferably the present invention is applied to a slurry phase polymerisation process/reactor. In a slurry process, the fresh inert hydrocarbon preferably is iso-butane.

The slurry polymerisation reactor is preferably a loop slurry polymerisation reactor. Such reactors are well-known, and comprise series of horizontal and/or vertical legs connected by elbows to form a continuous flow path. The preferred reactors according to the present invention comprise a series of vertical legs, such as 4, 6, 8 or more vertical legs, especially 4-8 vertical legs. The preferred reactors have a volume generally in the range 50 to 250 m³. The internal diameter of the reactors can vary, but is preferably from 450 to 800 mm, especially from 500 to 750 mm.

The slurry polymerisation reactor may have at least 2 withdrawal ports.

The withdrawal of polymer from the slurry polymerisation reactor may be performed continuously or discontinuously. Continuous withdrawal is preferred.

The fresh feed is preferably fresh comonomer. More preferably both fresh comonomer and fresh inert hydrocarbon are passed to the separator with the process stream.

In particular, it has surprisingly been found that by passing the fresh feeds to the separator with the process stream an increased concentration of the first component is recovered in the first stream. At the same time, the loss of more desired components, such as ethylene (monomer/second component) and heavier hydrocarbons is reduced.

For example, and in particular, passing a comonomer such as 1-hexene to the separator has surprisingly been found in increase the concentration of nitrogen recovered in the first stream, whilst reducing the amount of isobutane (inert hydrocarbon diluent) and ethylene (monomer) in said stream. Since at least a portion of the first stream is usually disposed of, for example by flare, the reduction in isobutane and ethylene in the first stream results in a reduced loss of said components.

In general, the process of the present invention can result in a relative increase in the proportion of second component fed to the separator which is recovered in the second stream of at least 5%, and preferably of at least 10%. (The “relative increase” is defined herein as the increase in proportion obtained when passing the fresh feed to the separator with the process stream compared to the proportion obtained without passing the fresh feed to the separator with the process stream). In absolute terms, the process of the present invention can result in an increase in the proportion of second component fed to the separator which is recovered in the second stream of at least 2 wt %, preferably at least 4 wt %, compared to the proportion obtained without passing the fresh feed to the separator with the process stream.

The separator in the first aspect of the present invention is operated at a pressure of 0.4 MPa (4 bar) or less. As noted above the process stream is preferably a stream which arises from the low pressure recovery system of the polymerisation process. The separator is itself part of the low pressure recovery system of the polymerisation process as is described further below.

In terms of temperature, the separator may be at any temperature which, in combination with the pressure, produces a first stream comprising the majority of the first component and a second stream comprising the second component and the majority of the fresh feed. The separator is preferably at a temperature of less than 0° C., for example less than −10° C., and most preferably less than −20° C., for example less than −30° C. In the first aspect of the present invention the pressure is 0.4 MPa (4 bar) or less, preferably 0.3 MPa (3 bar) or less, and most preferably 0.2 MPa (2 bar) or less.

In general, light components such as hydrogen, methane and nitrogen separate with very high specificity into the first stream, and in particular at least 90% of each of such components fed to the separator are recovered in the first stream. As a particular example, the first stream typically comprises essentially all, by which is meant over 99%, of the hydrogen and nitrogen fed to the separator.

Similarly, heavy components, such as 1-hexene and hexane separate with very high specificity into the second stream, again by which is meant greater than 90% of each of such components fed to the separator are recovered in the second stream. In fact, where the fresh liquid is 1-hexene (comonomer) typically over 99% of 1-hexene fed to the separator is recovered in the second stream.

Intermediate components, such as ethylene, ethane, propane and isobutane tend to pass into both streams in more similar amounts.

A yet further advantage of the present invention is that a proportion of undesired components which may be present in the fresh feeds can be separated therefrom in the first process stream, and thereby at least a portion of these are passed to flare without ever entering the polymerisation reactor. This can apply, for example, to ethane and propane impurities in iso-butane feeds. The effect of this is that feeds with increased amounts of such materials may be used as feedstreams with no or reduced detriment to the polymerisation process.

Another advantage of the present invention is therefore that either less highly specified feeds may be used, or pre-treatment of such streams prior to use may be reduced.

Although it is possible to also feed fresh comonomer and/or fresh inert hydrocarbon feeds directly to the polymerisation reactor, it is preferred that the majority of fresh comonomer passed to the reactor is passed via the claimed process and/or that the majority of fresh diluent passed to the reactor is passed via the claimed process.

More preferably, it is preferred that all of the fresh comonomer passed to the reactor is passed via the claimed process. Most preferably all of the fresh comonomer passed to the reactor is passed via the claimed process and all of the fresh inert hydrocarbon passed to the reactor is passed via the claimed process.

It should be noted that in the preferred process where the reactor is part of a slurry polymerisation process, the process stream typically also comprises significant quantities of diluent liquid. Generally, over 90% of the total isobutane fed to the separator is recovered in the second stream. In fact, the amount of diluent liquid in the low pressure process stream usually exceeds, often substantially, the amount of fresh diluent it is necessary to feed to the system to replace that lost.

In particular, averaged over time, the amount of fresh diluent is usually less than 5% of the total diluent feed to the separator. Further, although some fresh isobutane fed to the separator will be removed in the first vapour stream, not all of this stream is passed to flare. In fact, the make-up fresh diluent rate, which is also equal to the diluent loss rate from the polymerisation process, can be maintained the same in the process of the present invention as a polymerisation process where the fresh inert hydrocarbon (diluent) is not introduced into this separator as claimed.

The fresh feeds can be fed continuously to the separator, or may be fed intermittently. For example, due to the low make-up rates required for fresh diluent it is generally preferred to feed fresh diluent intermittently.

As noted above, another surprising advantage of the present invention is that by passing the fresh feeds to the separator impurities present in these feeds can also be removed i.e. the separator also provides some treatment of the fresh liquid feeds. The impurities can depend on the particular liquid feed, but for iso-butane, for example, can include lighter alkanes, such as propane, which whilst not directly detrimental can otherwise build-up in the process.

Nevertheless, some pre-treatment is still preferred.

Thus, in a second aspect, the present invention provides a process for the treatment of a fresh feed stream to be introduced into a polymerisation reactor, said process comprising

a) Passing the fresh feed stream to a first treatment step where it is treated to remove one or more impurities, and

b) Passing the fresh feed stream exiting the first treatment step with a process stream comprising a first component selected from hydrogen, nitrogen and methane and a second component which is a monomer to a second treatment step, which is a separator, to produce a first stream comprising the majority of the first component and a second stream comprising the second component and the majority of the fresh feed, and

c) Passing the second stream to the polymerisation reactor.

The fresh feed preferably comprises inert hydrocarbon or comonomer.

Where the fresh liquid stream comprises inert hydrocarbon the first treatment step may remove one or more of water and other oxygenated compounds, such as alcohols, MTBE and carbonyl compounds.

Where the fresh liquid stream comprises comonomer the first treatment step may remove one or more of water, MTBE, carbonyl compounds, chloride compounds, sulphur compounds, carbon monoxide and carbon dioxide.

Where it is desired to feed both fresh inert hydrocarbon and fresh comonomer, the fresh diluent and fresh comonomer may initially be separately treated in separate treatment steps in step (a), and then combined before passage to the separator.

Alternatively, the fresh inert hydrocarbon and fresh comonomer may be combined and treated in the same treatment step in step (a).

The preferred features of steps (b) and (c) of this second aspect are generally as for the first aspect of the present invention.

For example, the polymerisation reactor in this second aspect is preferably a slurry loop polymerisation reactor to which inert hydrocarbon is fed as a diluent.

Similarly, the separator is preferably at a pressure of 0.4 MPa (4 bar) or less, and most preferably is part of the low pressure recovery system.

The processes of the first and second aspects of the present invention may each be applied to the provision of fresh feeds to a polymerisation process comprising high and low pressure recovery systems. The term “recovery system” as used herein refers to a system used to separate components which it is desired to recycle to the reactor from desired product in a reactor effluent, and to recycle such components to the reactor. In particular, said polymerisation process may comprise the steps of:

1) Polymerising a monomer and a comonomer in a polymerisation reactor,

2) Withdrawing an effluent stream comprising solid polymer and a mixture comprising unreacted monomer and unreacted comonomer, and passing the effluent to a high pressure recovery system comprising

-   -   a. a high pressure separation step for separating a vapour         comprising unreacted monomer and unreacted comonomer from said         solids, and     -   b. a recycle system for recycling at least a portion of the         vapour to the polymerisation reactor,

3) Passing the solids from the high pressure recovery system to a low pressure recovery system comprising

-   -   a. a low pressure separation step for separating further         unreacted monomer and unreacted comonomer from said solids, and     -   b. a recycle system comprising a vapour/liquid separator for         recycling at least a portion of the unreacted monomer and         unreacted comonomer.

The polymerisation process is preferably a slurry polymerisation process, in which the polymerisation process may comprise the steps of:

1) Polymerising a monomer and a comonomer in the presence of a diluent in a polymerisation reactor,

2) Withdrawing an effluent stream comprising solid polymer and a mixture comprising diluent, unreacted monomer and unreacted comonomer, and passing the effluent to a high pressure recovery system comprising

-   -   a. a high pressure separation step for separating a vapour         comprising diluent, unreacted monomer and unreacted comonomer         from said solids, and     -   b. a recycle system for recycling at least a portion of the         vapour to the polymerisation reactor,

3) Passing the solids from the high pressure recovery system to a low pressure recovery system comprising

-   -   a. a low pressure separation step for separating further         diluent, unreacted monomer and unreacted comonomer from said         solids, and     -   b. a recycle system comprising a vapour/liquid separator for         recycling at least a portion of the further diluent, unreacted         monomer and unreacted comonomer.

As an example in a slurry polymerisation process, high pressure recovery systems are known and widely operated to enable a majority of the diluent, monomer and comonomer to be vaporised and separated from the polymer solids at relatively high pressure, such that the vapour can be condensed without compression for recycle to the reactor. The separated polymer solids are then passed to a low pressure system for recovery of remaining diluent, monomer and comonomer. A low pressure recovery system, in contrast to the high pressure recovery system, generally leads to recovered components, such as diluent, monomer and comonomer, which must be compressed (or further cooled) in order to be able to condense them prior to recycle to the reactor.

(“Compression” refers to a process of increasing the pressure (“compressing”) a vapour. This is a relatively energy intensive process. Once in the form of liquids, liquids can be pumped to increased pressure with relatively less difficulty. Avoiding “compression”, for example by condensing without compression, is highly desirable.)

Examples of such systems can be found, for example, in WO 2005/003188 which discloses the use of a higher pressure flash stage followed by a lower pressure flush stage. However, processes are also known where the lower pressure stage is a flash stage rather than a flush stage, or where both flashing and flushing occur in a single stage. (It can be noted that a flush stage can also be referred to as a “purge stage”. The term “flush” is used herein for such steps to avoid any confusion with process purges, which are steps whereby streams are removed from a polymerisation process, for example to flare. The term “purge” as used herein therefore refers to a stream which is removed from the process rather than a flush step.)

The terms “high pressure” and “low pressure” are used herein principally to indicate the relative pressures of the two recovery systems.

Generally, however, “high pressure” as used herein generally refers to streams and stages which are at a pressure of 0.5 MPa (5 bar) and above, and usually 0.7 MPa (7 bar) and above, and “low pressure” generally refers to streams and stages which are at a pressure of less than 0.5 MPa (5 bar), usually less than 0.4 MPa (4 bar).

(Thus, a high pressure recovery system has a pressure of 0.5 MPa and above, whilst a low pressure recovery system has a pressure of less than 0.5 MPa.)

There is no specific maximum pressure, but for practical purposes the term “high pressure” is usually less 2 MPa (20 bar), and usually less than 1.5 MPa (15 bar). Further, although pressures less than atmospheric pressure are possible, the “low pressure” systems are usually at a pressure of at least 0.1 MPa (1 bar).

For avoidance of any doubt, unless otherwise indicated, values of pressure as quoted herein are “absolute” values rather than “gauge” values.

The high and low pressure separation steps in such systems above are typically vapour/solids separation steps, such as flash vessels and flush vessels.

The separator to which the fresh feed is passed according to the first and second aspects of the present invention is preferably the “vapour/liquid separator” in the low pressure recovery system of a process as defined above.

In a most preferred embodiment as applied to such a polymerisation process, a portion of the vapour recovered in step 2(a) is condensed, let-down in pressure, and also passed to the vapour/liquid separator.

In general, this would be expect to be disadvantageous because any recovered streams let-down in pressure have to be recompressed to be re-used. To avoid the requirement for this as much as possible is exactly the reason why high pressure separation systems are used to try to maximise high pressure recovery of reaction components.

Surprisingly, however, it has been found that passing a portion of the vapour recovered at high pressure to the vapour/liquid separator (after condensing and deliberately letting down the pressure) results in yet further enhancement in the separations process, and in particular, in an overall reduction in desired components lost to flares.

The portion of the vapour separated in step 2(a) which is passed to the vapour/liquid separator generally comprises at least 0.5% by weight of the vapour separated in step 2(a), such as at least 1% by weight or at least 5% by weight of the vapour separated in step 2(a).

Further, where the separator is operated at a pressure of less than 0.4 MPa (4 bar) and at a temperature of less than −10° C. (i.e. as a low pressure and low temperature separator) a yet further advantage may be obtained because at such low temperatures condensation of the components as the second stream can occur at relatively low pressures compared to low pressure streams at relatively higher temperatures. Thus, only a relatively small pressure increase is required to obtain condensation of the stream. This allows the use of devices which need only provide a relatively small pressure increase, by which is meant a maximum of 0.5 MPa (5 bar). Any device or assembly of devices arranged in series or in parallel may be used which increase the pressure of a gas or a mixture of gases by a maximum 0.5 MPa (5 bar), and preferably by a maximum 0.3 MPa (3 bar). Examples of such devices include blowers (such as positive displacement blowers) and screw compressors. Such devices are generally cheaper and simpler to operate than devices which can provide higher pressure increases, such as reciprocating or labyrinth compressors. The condensed stream once formed can then be pumped to reaction pressure without a requirement for compression. In the fourth aspect, the portion of the vapour recovered in step 2(a) may be passed directly to the vapour/liquid separator or may be passed to the earlier treatment step with the fresh feed.

The process of the first and second aspects of the present invention may also be advantageously applied to a polymerisation process operating in two or more reactors. The operation of two loop reactors in series, for example, is well-known.

In particular, the fresh feed may be passed to a separator as claimed to produce a second stream, and a first portion of said second stream is passed to a first of said at least 2 reactors and a second portion of said second stream is passed to a second of said at least 2 reactors.

It is preferred that no further fresh feeds of fresh diluent or fresh comonomer are passed to the first reactor or no further fresh feeds of fresh diluent or fresh comonomer are passed to the second reactor. Most preferably no further fresh feeds of fresh diluent or fresh comonomer are passed to the first reactor and no further fresh feeds of fresh diluent or fresh comonomer are passed to the second reactor.

As noted above, the present invention generally provides improved separation of the first component from the second component (monomer).

Thus, in further aspects, the present invention provides a process for improving the separation of a first component selected from hydrogen, nitrogen and methane from a second component which is a monomer by passing a process stream comprising said first and second components to a separator, said improvement comprising one or more of the following:

1) also passing to the separator fresh comonomer,

2) also passing to the separator at least one fresh feed selected from fresh comonomer and fresh inert hydrocarbon whilst operating the separator at a pressure of 0.4 MPa or less, and

3) also passing to the separator fresh inert hydrocarbon where said process stream also comprises a third component which is a comonomer.

The first component is preferably nitrogen.

The preferred features are generally as described for the first and second aspects above.

The present invention allows to obtain a polymerisation process which has a high efficiency for desired components of the final polymer, such as monomer, but “low” efficiency for other components (such as impurities).

As used herein, “efficiency” is a measure of the amount of a particular material which is fed and which is not purged. For example, monomer efficiency is the amount of monomer fed which is not purged.

The monomer efficiency is a measure of the amount of the monomer which ends up in the polymer product, and is determined from the amount of fresh monomer fed to a process and the amount of monomer which is purged. The monomer purge rate may be determined from the purge flow and the concentration of monomer in the purge stream, which can be measured by GC, for each purge stream present. The efficiency may be determined instantaneously, based on flow rate measurements at a particular time, but preferably is determined over a period of time, for example based on averaged instantaneous measurements or on total amounts fed and purged determined over a period of at least several hours, as this generally gives a more accurate measurement. The monomer efficiency is determined by subtracting the amount purged from the amount fed, and then dividing the result by the amount fed. This answer is multiplied by 100 to give the efficiency as a percentage.

The process of the present invention is able to provide a monomer efficiency in excess of 99.5%, for example of 99.6% and above, and most preferably of 99.7% and above.

It is worth noting that, whilst monomer efficiencies of polymerisation processes are generally very high (above 99%), at the scale of commercial polymerisation processes even what appear as relatively minor increases in efficiency can result in significant cost savings, as well as significant reductions in hydrocarbon emissions or combustion products from hydrocarbon emissions (when flared). For example, in a process producing 50 tonnes/hour of polymer, an increase in monomer efficiency by only 0.1% is still a reduction in monomer losses of 50 kg/hour.

In contrast to a high monomer efficiency, it has been found that a low hydrogen efficiency of a polymerisation process can be advantageous. In particular, hydrogen is more cost effectively flared than recycled and recovered to the overall polymerisation process. An advantage of relatively low hydrogen efficiencies is that other impurities which can be present in fresh hydrogen feeds, such as methane and CO, are also efficiently purged from the system via the purge streams, and purification of fresh hydrogen feed via PSA can be avoided.

The present invention can result in a polymerisation process which preferably has a hydrogen efficiency, measured of the amount of the fed hydrogen which is not purged of 80% or less, preferably of 70% or less, and most preferably of 60% or less.

The hydrogen efficiency may be determined in a similar manner to the monomer efficiency, and in particular by determining the amount of hydrogen purged from the purge flow and the hydrogen concentration in the purge stream, which can be measured by GC, for each purge stream present and comparing this to the amount of hydrogen fed to the process.

The present invention will now be illustrated by reference to the following examples.

EXAMPLES Comparative Example

Ethylene is polymerised in two slurry loop reactors in series to produce a bimodal polyethylene with a density of 950 kg/m³ and a melt index MI5 of 0.2 g/10 min. The total production rate is 37.5 tonnes/hour.

In the first reactor ethylene is polymerised using a Ziegler-Natta catalyst, in the presence of hydrogen and with isobutane as diluent. Polymer from the first reactor is passed to a second reactor wherein further ethylene is polymerised in the presence of 1-hexene as comonomer, again in the presence of hydrogen and isobutane.

Polymer slurry is withdrawn from the second reactor and passed via a slurry heater, in which the liquid components of the slurry are vaporised to a separating tank at a pressure of 0.9 MPa.

The vapour from the separating tank overhead is further treated, condensed and recycled to the reactors via a high pressure recovery system.

Polymer solids are withdrawn from the separating tank for further processing in a flush vessel at a pressure of 0.35 MPa. The flushing takes place by contact in two vertically orientated stages with polymer being introduced at the top and withdrawn from the base of the vessel, and with a recycled flush gas being introduced into the upper stage and nitrogen being introduced into the lower stage.

A mixture of the flush gases and recovered diluent/monomer is recovered from the top of the flush vessel.

The stream is pressurised, combined with a recycle from a heavies separation unit, cooled and the mixture passed to a separator at a pressure of 0.3 MPa and at a temperature of −35° C.

The total flow to the separator is approximately 6200 kg/hr and comprises isobutane, 1-hexene, nitrogen, ethane, ethylene, propane, hexane, methane and hydrogen. From the base of the separator is recovered a stream at a flow rate of approximately 5140 kg/hr.

The base stream comprises 99.8% of the 1-hexene and hexane fed to the separator, as well as 94.5% of the isobutane and 32.5% of the ethylene.

The base stream is recycled, after compression, to the polymerisation process.

Overhead from the separator is recovered a stream at a flow rate of 1060 kg/hr comprising nitrogen, isobutane, ethane, ethylene and propane with smaller amounts of 1-hexene, hexane, methane and hydrogen.

The overhead stream comprises 93.7% of the methane, 98.6% of the nitrogen and 99.6% of the hydrogen fed to the separator.

The majority of this stream is recycled to the flush vessel. The remainder of this stream is passed to a flare. 235 kg/hr of nitrogen is flared, along with 191 kg/h of ethylene, 179 kg/h of isobutane, 4.8 kg/hr of propane, 11.5 kg/hr of methane, 0.40 kg/hr of 1-hexene and hexane and 10.2 kg/hr of hydrogen.

In this comparative example the fresh 1-hexene is fed directly to the reactors and the fresh isobutane in the high pressure recovery system.

Example 1

The Comparative Example is repeated except that the stream passed to the separator is, prior to the cooling step, mixed with 880 kg/hr of fresh 1-hexene (99% 1-hexene, 1% hexane).

The total flow to the separator is approximately 7050 kg/hr.

From the base of the separator is recovered a stream at a flow rate of approximately 6050 kg/hr.

The base stream comprises 99.9% of the 1-hexene and hexane fed to the separator, as well as 95.2% of the isobutane and 35.3% of the ethylene.

The base stream is recycled, after compression, to the polymerisation process. Overhead from the separator is recovered a stream at a flow rate of 1000 kg/hr.

The overhead stream comprises 92.9% of the methane, 98.4% of the nitrogen and 99.5% of the hydrogen fed to the separator.

The majority of this stream is recycled to the flush vessel. The remainder of this stream is passed to a flare. 235 kg/hr of nitrogen is flared, along with 182 kg/h of ethylene, 156 kg/h of isobutane, 4.4 kg/hr of propane, 11.5 kg/hr of methane, 1.16 kg/hr of 1-hexene and hexane and 10.3 kg/hr of hydrogen.

By comparison to the Comparative Example it can be seen that, by passing the fresh 1-butene feed to the low pressure system, an increased amount of ethylene and isobutane are recovered in the base stream, and the losses of ethylene and isobutane in the flare are reduced. In particular, the addition of 1-hexene reduces the losses of isobutane by approximately 23 kg/hr, or 13%, and the losses of ethylene by approximately 9 kg/hr, or 5%, compared to the Comparative Example.

Example 2

The Comparative Example is repeated except that the stream passed to the separator is, prior to the cooling step, mixed with 176 kg/hr of fresh isobutane (97% isobutane, 3% propane).

The total flow to the separator is approximately 6350 kg/hr.

From the base of the separator is recovered a stream at a flow rate of approximately 5320 kg/hr.

The base stream comprises 99.8% of the 1-hexene and hexane fed to the separator, as well as 94.7% of the isobutane and 33.3% of the ethylene.

The base stream is recycled, after compression, to the polymerisation process.

Overhead from the separator is recovered a stream at a flow rate of 1030 kg/hr. The overhead stream comprises 93.5% of the methane, 98.6% of the nitrogen and 99.6% of the hydrogen fed to the separator.

The majority of this stream is recycled to the flush vessel. The remainder of this stream is passed to a flare. 235 kg/hr of nitrogen is flared, along with 188 kg/h of ethylene, 178 kg/h of isobutane, 4.8 kg/hr of propane, 11.4 kg/hr of methane, 0.39 kg/hr of 1-hexene and hexane and 10.15 kg/hr of hydrogen

Compared to the Comparative Example, and although the differences are of smaller magnitude, by passing fresh isobutane directly in the low pressure system in this Example, rather than directly to the reactors, as in the Comparative Example, the amount of ethylene purged is slightly reduced.

Example 3

The Comparative Example is repeated except that the stream passed to the separator is, prior to the cooling step, mixed with 880 kg/hr of fresh 1-hexene (99% 1-hexene, 1% hexane) and 176 kg/hr of fresh isobutane (97% isobutane, 3% propane).

The total flow to the separator is approximately 7230 kg/hr. From the base of the separator is recovered a stream at a flow rate of approximately 6230 kg/hr.

The base stream comprises 99.9% of the 1-hexene fed to the separator, as well as 95.3% of the isobutane and 36% of the ethylene.

The base stream is recycled, after compression, to the polymerisation process. Overhead from the separator is recovered a stream at a flow rate of 1000 kg/hr.

The overhead stream comprises 92.7% of the methane, 98.4% of the nitrogen and 99.5% of the hydrogen fed to the separator.

The majority of this stream is recycled to the flush vessel. The remainder of this stream is passed to a flare. 234 kg/hr of nitrogen is flared, along with 179 kg/h of ethylene, 156 kg/h of isobutane, 4.4 kg/hr of propane, 11.44 kg/hr of methane, 1.12 kg/hr of 1-hexene and hexane and 10.28 kg/hr of hydrogen

As with Example 1, by comparison to the Comparative Example it can be seen that an increased amount of ethylene and isobutane are recovered in the base stream, and the losses of ethylene and isobutane in the flare are reduced. In particular, the addition of 1-hexene and isobutane reduces the losses of isobutane by approximately 23 kg/hr, or 13%, and the losses of ethylene by approximately 12 kg/hr, or 6%, compared to the Comparative Example. 

1-16. (canceled)
 17. A process for the introduction of a fresh feed selected from fresh comonomer and fresh inert hydrocarbon to a polymerisation reactor wherein the polymerisation reactor is part of a polymerisation process comprising high and low pressure recovery systems, said high pressure recovery system being at a pressure of 0.5 MPa (5 bar) or above and said low pressure recovery system being at a pressure of less than 0.5 MPa (5 bar), which process comprises passing said fresh feed and a process stream comprising a first component selected from hydrogen, nitrogen and methane and a second component which is a monomer to a separator which is part of the low pressure recovery system and is at a pressure of 0.4 MPa or less to produce a first stream comprising the majority of the first component and a second stream comprising the second component and the majority of the fresh feed, and passing the second stream to the polymerisation reactor.
 18. A process according to claim 17 where the fresh feed is fresh comonomer.
 19. A process according to claim 17 where the separator is a single stage separation vessel.
 20. A process according to claim 17 wherein the polymerisation reactor is a slurry phase reactor and the fresh inert hydrocarbon is a component which is utilised as a diluent in the process.
 21. A process according to claim 17 wherein both fresh comonomer and fresh inert hydrocarbon are passed to the separator with the process stream.
 22. A process according to claim 17 where the separator is at a temperature of less than 0° C., for example less than −10° C., and most preferably less than −20° C., for example −35° C. and/or where the separator is at a pressure of 0.3 MPa or less, and most preferably 0.2 MPa or less.
 23. A process according to claim 17 wherein the majority of fresh comonomer passed to the reactor is passed via the claimed process and/or the majority of fresh inert hydrocarbon passed to the reactor is passed via the claimed process, and preferably wherein all of the fresh comonomer passed to the reactor is passed via the claimed process.
 24. A process for the treatment of a fresh feed stream to be introduced into a polymerisation reactor, said process comprising a) Passing the fresh feed stream to a first treatment step where it is treated to remove one or more impurities, and b) Passing the fresh feed stream exiting the first treatment step with a process stream comprising a first component selected from hydrogen, nitrogen and methane and a second component which is a monomer to a second treatment step which is a separator to produce a first stream comprising the majority of the first component and a second stream comprising the second component and the majority of the fresh feed, and c) Passing the second stream to the polymerisation reactor.
 25. A process according to claim 24 wherein the fresh feed comprises inert hydrocarbon or comonomer.
 26. A process according to claim 24 wherein the polymerisation reactor is a slurry loop polymerisation reactor to which inert hydrocarbon is fed as a diluent.
 27. A process according to claim 24 wherein the polymerisation reactor is part of a polymerisation process comprising high and low pressure recovery systems, said high pressure recovery system being at pressure of 0.5 MPa or above and said low pressure recovery system being at pressure of less than 0.5 MPa, the separator being part of the low pressure recovery system and being at a pressure of 0.4 MPa or less.
 28. A process according to claim 27 wherein the separator is at a temperature of less than 0° C., for example less than −10° C., and most preferably less than −20° C., for example −35° C. and/or where the separator is at a pressure of 0.3 MPa or less, and most preferably 0.2 MPa or less.
 29. A process according to claim 17 wherein the polymerisation process comprises the steps of: 1) Polymerising a monomer and a comonomer in a polymerisation reactor, 2) Withdrawing an effluent stream comprising solid polymer and a mixture comprising unreacted monomer and unreacted comonomer, and passing the effluent to a high pressure recovery system comprising a. a high pressure separation step for separating a vapour comprising unreacted monomer and unreacted comonomer from said solids, and b. a recycle system for recycling at least a portion of the vapour to the polymerisation reactor, 3) Passing the solids from the high pressure recovery system to a low pressure recovery system comprising a. a low pressure separation step for separating further unreacted monomer and unreacted comonomer from said solids, and b. a recycle system comprising a vapour/liquid separator for recycling at least a portion of the unreacted monomer and unreacted comonomer, said separator to which the fresh feed is passed being the “vapour/liquid separator” of step 3(b).
 30. A process according to claim 29 wherein a portion of the vapour recovered in step 2(a) is condensed, let-down in pressure, and also passed to the vapour/liquid separator of step 3(b).
 31. A process according to claim 17 wherein the polymerisation reactor has a volume of at least 50 m³.
 32. A process according to claim 17 wherein less than 50 wt % of the second component (monomer) is recovered in the second stream.
 33. A process according to claim 24 wherein the polymerisation reactor has a volume of at least 50 m³.
 34. A process according to claim 27 wherein the polymerisation process comprises the steps of: 1) Polymerising a monomer and a comonomer in a polymerisation reactor, 2) Withdrawing an effluent stream comprising solid polymer and a mixture comprising unreacted monomer and unreacted comonomer, and passing the effluent to a high pressure recovery system comprising a. a high pressure separation step for separating a vapour comprising unreacted monomer and unreacted comonomer from said solids, and b. a recycle system for recycling at least a portion of the vapour to the polymerisation reactor, 3) Passing the solids from the high pressure recovery system to a low pressure recovery system comprising a. a low pressure separation step for separating further unreacted monomer and unreacted comonomer from said solids, and b. a recycle system comprising a vapour/liquid separator for recycling at least a portion of the unreacted monomer and unreacted comonomer, said separator to which the fresh feed is passed being the “vapour/liquid separator” of step 3(b).
 35. A process according to claim 29 wherein the polymerisation reactor has a volume of at least 50 m³.
 36. A process according to claim 34 wherein the polymerisation reactor has a volume of at least 50 m³. 